Three-Dimensional Finite Element Analysis of Conventional and Ultrasonic Vibration Assisted Micro-Drilling on PCB

Recent advancement in society’s demands has forced industries to produce more and more precise micro parts. With an advancement in engineering sciences, current manufacturers in various fields such as aerospace, medical, electronics, automobile, biotechnology, etc. have achieved the potential to fabricate miniaturized products, but with numerous technical challenges. Dimensional accuracy and surface integrity of the machined components are the key challenges and at the same time, cost minimization is strongly desired. To meet these challenges and demands, improvements in machining regarding new procedures, tooling, tool materials and modern machine tools are highly essential. Micromachining has shown potential to achieve the fast-growing needs of the present micro manufacturing sector. Additionally, new machining techniques like ultrasonic machining, laser drilling, etc. have been developed as an alternative source to reduce obstructions caused during macro/micro machining. The present research aims to perform three-dimensional (3D) finite element dynamic analysis for micro-drilling of multi-layer printed circuit boards (PCBs). Both conventional and ultrasonic vibration assisted micro-drilling (UVAMD) FE simulations have been compared to predict and evaluate the effect of process parameters on the output responses like stress generation and reaction forces and burr formation on the workpiece surfaces. The Lagrangian based approach is followed for the FE simulation including the mass and inertial properties of the proposed FE model. The predicted FE results are compared with the past experimental work for thrust force evaluation and burr formation on workpiece surfaces. The present work is supported with modal and harmonic analysis of stepped and conical horns along with micro drill bit. Here, horns made up of Aluminum 6061-T6, Titanium and Mild steel are chosen with micro drill bit of 0.3 mm diameter with varying tool materials (Tungsten carbide and High speed steel). The effects of natural frequencies with different mode shapes within the range of 15-30 kHz are shown. The frequency responses of micro drill with displacement conditions have been presented for longitudinal modes. The present simulation results will be helpful to conduct proper experimentation in order to achieve efficient machining and surface finish. The results enumerate that the drilling parameters have a strong influence on thrust forces and stresses occurring in micro-drilling. Ultrasonic assisted micro-drilling has a good potential in reduction of forces generated by vii selecting proper machining parameters. The FE simulation of UVA micro machining can further be enhanced and extended to various materials like plastics, sheet metal, other PCBs, etc. to predict the performance with varying machining and geometrical parameters